Wuhan Grat Control Valve Co., Ltd.

Anwendungshintergrund In den Wärmebehandlungsprozessen der metallurgischen Industrie sind kontinuierliche Glühöfen Kernausrüstung zur Herstellung hochwertiger kaltgewalzter Stahlbänder. Ein großes Stahlwerk in Hubei benötigte eine präzise Durchflussregelung in der Verbrennungsluftleitung seiner kontinuierlichen Glühlinie.Unter hochfrequenten Anpassungen, litten traditionelle Steuerungsmethoden unter geringer Präzision, langsamer Reaktion und häufigen Ausfällen, während die GRAT Electric Ventilation Butterfly Valve eine hochpräzise, zuverlässige Luftregelungslösung. Betriebsbedingungen Diese Anwendung stellt hohe Anforderungen an die Ventilleistung, mit folgenden spezifischen Betriebsparametern: Anwendung: Verbrennungsluftzufuhrleitung für einen kontinuierlichen Glühofen Produkt: GRAT Low-Load Electric Ventilation Butterfly Valve Medium: Vorerhitzte Luft Temperatur: 120°C – 300°C (unterliegt häufigen Schwankungen) Nenndruck: PN10 Größe: DN200 Anschluss: Flansch Steuersignal: Modulierende Steuerung, 4-20mA Betriebsumgebung: Industrielle Werkstatteinstellung, erfordert Geräte mit hoher Schutzart und Dauerbetriebsfähigkeit. Konstruktionslebensdauer: ≥ 5 Jahre Produktvorteile & Eigenschaften Das GRAT Electric Ventilation Butterfly Valve wurde für die rauen Umgebungen von Glühöfen entwickelt: Präzise Proportionalregelung: Verfügt über einen Hochleistungsantrieb mit Positioniergenauigkeit bis zu ±0,5%. Hält Schwankungen der Ofenatmosphäre innerhalb von ±2°C. Hervorragende Hochtemperaturbeständigkeit: Konstruiert aus Edelstahl SUS304, behält über 85% seiner Festigkeit bei 300°C. Ein stromlinienförmiges Scheibendesign reduziert das erforderliche Drehmoment um 40%, wodurch Energie gespart und Verschleiß reduziert wird. Hohe Zuverlässigkeit & lange Lebensdauer: Eingebauter Überlastschutz verhindert Schäden durch Verklemmen. Erreicht eine Dichtleckrate unter 0,01% für langfristige, hochfrequente Zyklen. Einfache Installation & Wartung: Standard-Flanschanschluss für schnelle Installation. Modulares Design gewährleistet MTTR von weniger als 30 Minuten für Schlüsselkomponenten. Leistungsergebnisse Seit der Inbetriebnahme im Juli 2017 hat das Ventil außergewöhnliche Ergebnisse geliefert: Verbesserte Regelgenauigkeit: Die Schwankung des Verbrennungsluftvolumens wurde von ±15% auf innerhalb von ±6% reduziert. Die Temperaturdifferenz in der Ofenzone wurde auf innerhalb von ±5°C. Bewährte Zuverlässigkeit: Das Ventil hat kontinuierlich ohne Ausfall über 70 Monate gearbeitet und über 250.000 Zyklen. Greifbare wirtschaftliche Vorteile: Die Produktausbeute stieg von 92% auf 96,5%, während gleichzeitig die Betriebskosten pro Ventil gesenkt wurden. Außergewöhnliche Haltbarkeit: Nach dem Betrieb 40% über seiner Konstruktionslebensdauer befindet sich das Ventil weiterhin in ausgezeichnetem Zustand und liefert einen Gesamt-ROI von über 150%. Das GRAT Low-Load Electric Ventilation Butterfly Valve demonstriert robuste Anpassungsfähigkeit und Zuverlässigkeit in Hochtemperatur-Prozesssteuerungsanwendungen mit hohem Bedarf in der metallurgischen Industrie. Für eine Electric Ventilation Butterfly Valve-Lösung, die Effizienz und Haltbarkeit garantiert, ist GRAT Ihr zuverlässiger Partner für Neuprojekte und Geräte-Upgrades.

Application Background In the heat treatment processes of the metallurgical industry, continuous annealing furnaces are core equipment for producing high-quality cold-rolled steel strips. A large steel plant in Hubei needed precise flow control in the combustion air pipeline of its continuous annealing line. Under high-frequency adjustments, Traditional control methods suffered from low precision, slow response, and frequent failures, while GRAT Electric Ventilation Butterfly Valve developed a high-precision, reliable air regulation solution. Operating Conditions This application poses severe challenges to valve performance, with specific operating parameters as follows: Application: Combustion air supply pipeline for continuous annealing furnace Product: GRAT Low-Load Electric Ventilation Butterfly Valve Medium: Preheated Air Temperature: 120°C – 300°C (subject to frequent fluctuations) Nominal Pressure: PN10 Size: DN200 Connection: Flanged Control Signal: Modulating Control, 4-20mA Operating Environment: Industrial workshop setting, requiring equipment with a high protection rating and continuous operation capability. Design Life: ≥ 5 years Product Advantages & Features The GRAT Electric Ventilation Butterfly Valve is engineered for the harsh environments of annealing furnaces: Precise Proportional Control: Features a high-performance actuator with positioning accuracy up to ±0.5%. Maintains furnace atmosphere fluctuations within ±2°C. Excellent High-Temperature Resistance: Constructed from SUS304 stainless steel, retaining over 85% of its strength at 300°C. A streamlined disc design reduces required torque by 40%, saving energy and reducing wear. High Reliability & Long Service Life: Built-in overload protection prevents damage from jamming. Achieves a seal leakage rate below 0.01% for long-term, high-frequency cycling. Easy Installation & Maintenance: Standard flanged connection for quick installation. Modular design ensures MTTR is less than 30 minutes for key components. Performance Results Since commissioning in July 2017, the valve has delivered exceptional results: Improved Control Accuracy: Combustion air volume fluctuation was reduced from ±15% to within ±6%. Furnace zone temperature difference was lowered to within ±5°C. Proven Reliability: The valve has operated continuously without failure for over 70 months, accumulating over 250,000 cycles. Tangible Economic Benefits: Product yield rate increased from 92% to 96.5%, while simultaneously reducing the operating cost per valve. Exceptional Durability: After operating 40% beyond its design life, the valve remains in excellent condition, delivering a total ROI by over 150%. Conclusion: The GRAT Low-Load Electric Ventilation Butterfly Valve demonstrates robust adaptability and reliability in high-temperature, high-demand process control applications within the metallurgical industry. For an Electric Ventilation Butterfly Valve solution that guarantees efficiency and durability, GRAT is your trusted partner for both new projects and equipment upgrades.

Valve Installation direction – a seemingly simple detail that directly impacts sealing performance and service life – is often overlooked in industrial pipeline and equipment maintenance. Especially when space is tight, a common question arises: “If it doesn’t fit vertically, can it be installed horizontally, or even upside down?” The answer isn’t universal; it depends entirely on the valve type and its internal design. Valves That MUST Be Installed in a Specific Direction First, let’s discuss valves that require strict adherence to installation direction, such as solenoid valves and pneumatic diaphragm valves. Incorrect Valve Installation for these types can lead to malfunction or rapid failure. For instance, a common pilot-operated solenoid valve relies on the media pressure differential to drive the valve core. If installed backwards, pressure can block the core, preventing it from opening even when energized. Even if it manages to open, the seal will wear out prematurely due to uneven force. Similarly, an upside-down Valve Installation for a pneumatic diaphragm valve puts constant stress on the diaphragm from gravity, leading to deformation, folding, reduced sealing precision, and a significantly shorter lifespan. Therefore, for these valves, you must follow the media flow direction indicated by the arrow on the valve body; never compromise due to space constraints. Valves with Flexible Installation Directions One category is electric valves – like electric ball valves and electric butterfly valves. These generally allow 360-degree installation in any orientation. Why such flexibility? The key lies in their design: their actuator typically uses a motor with gear transmission, which is unaffected by gravity. Regardless of orientation, power transmission efficiency remains above 95%. Sealing often involves O-rings combined with metal sealing surfaces, where the sealing pressure is controlled by bolt preload and is independent of the installation angle. Therefore, if vertical space is limited, an electric ball valve can be installed horizontally or even inverted in a ceiling plenum without compromising performance, making its Valve Installation highly adaptable. Another common category is pneumatic valves, such as pneumatic ball valves and pneumatic gate valves. They generally permit horizontal installation, but one critical point demands attention – the position of accessories, particularly the filter regulator. This component filters moisture and impurities from the compressed air and regulates pressure. Its bottom usually has a drain port. During Valve Installation, this drain port must face downwards. If it faces up or sideways, condensate cannot drain, accumulating inside the valve body. This leads to air pressure fluctuations, sluggish valve operation, and, more severely, moisture entering the cylinder, causing piston rust and seizure. For a horizontal Valve Installation, adjust the accessory bracket to ensure the drain port is vertically downward, leaving at least 10 cm of space for drainage. Solution for Valve Installation in Tight Spaces Guidelines for Valve Installation Direction When Space is Limited Valve Type Horizontal/Upside-Down Installation Allowed? Core Requirements and Reasons Solenoid Valve Strictly Forbidden Must be installed strictly according to the arrow on the valve body. Reverse installation can prevent the valve core from opening or cause rapid seal wear. Pneumatic Diaphragm Valve Strictly Forbidden Must be installed vertically upright. Inverted installation causes the diaphragm to deform under constant gravity pull, leading to seal failure. Electric Valve Allowed Supports 360° installation in any orientation. Its gear drive and seal design are unaffected by gravity direction. Pneumatic Valve Conditionally Allowed The valve body can be installed horizontally, but you must ensure the filter regulator’s drain port is vertically downward to prevent water accumulation and subsequent failure. Finally, here are two practical tips for any Valve Installation project: First, confirm the valve type to determine if it has orientation restrictions. Second, check accessory requirements, like the orientation of the filter regulator on pneumatic valves. Never assume based on past experience, as this easily leads to operational failures. When facing installation space limitations, consider our newly launched IoT Mini Electric Valve – engineered for compact spaces and high-precision control. This electric actuator features an integrated, compact design, with a volume one-third smaller than comparable torque products, yet it delivers a powerful 50 NM of torque. It supports 360° installation in any orientation, perfectly solving the challenge of insufficient vertical installation space. It supports AC220V or DC24V input, consumes only 10W of power, and fits ball valves up to DN40. Equipped with PWM stepless speed regulation and 0.5% high-precision control, it operates smoothly and adjusts accurately. The built-in brushless motor, integrated OLED Chinese status display, support for various signal feedback, and Modbus communication make it the ideal choice for flexible Valve Installation and reliable control in industrial automation systems. Small size, strong performance, and unrestricted installation orientation – the IoT Mini opens up new possibilities for your space-constrained automation systems. Welcome to learn more about our product details and inquire for custom solutions.

In PTA production plants within the chemical industry, the long-term stable operation of high-temperature and high-pressure steam control valves is crucial for the safety and economy of the entire process system. A PTA plant experienced control valve stem leakage in its steam regulation system. This valve leakage issue resulted not only in energy waste but also posed a threat to production safety. This GRAT case study will systematically analyze the cause of this valve leakage failure and provide a solution, offering a reference for valve selection and maintenance in similar working conditions. Technical Specifications Application: High-Temperature Steam Regulation System, PTA Chemical PlantMedium: Superheated SteamBody Material: WCBConnection Type: FlangedActuator Type: PneumaticOperating Temperature: 385℃Operating Pressure: 4.3MPaCommissioning Date: December 2024Installation Location: Steam Main Line, PTA Plant After approximately six months of continuous operation, significant steam leakage was observed at the valve stem position of this control valve. The rate of valve leakage gradually increased over time, severely impacting production safety and environmental performance. Troubleshooting & Analysis Upon arrival, the GRAT technical support team disassembled the faulty control valve for inspection and identified the following issues: A severe leakage path was present in the stuffing box area. The original PTFE packing showed obvious signs of aging and hardening. Some packing rings were severely worn and had lost their elastic sealing capability. Root Cause Analysis:PTFE packing is prone to hardening and aging in high-temperature environments. Its sealing performance degrades significantly with large temperature fluctuations. The steam temperature in this application reached 385℃, far exceeding the normal service temperature limit for PTFE packing (around 200℃). This caused rapid packing failure, leading directly to the observed steam valve leakage. Key factors influencing potential valve leakage include: Loose gland bolts with insufficient preload (e.g., due to long-term vibration) Worn or scratched valve stem surface (e.g., from solid particles in the medium) Incorrect packing installation methods (e.g., packing ring cuts not staggered) Use of packing material unsuitable for the service conditions (e.g., standard packing in high-temperature applications) Solution & Implementation Based on the specific site conditions, our technical personnel developed a targeted solution to stop the valve leakage: Packing Material Replacement: All original PTFE packing was replaced with flexible graphite packing. This material offers a wide temperature range (-200℃ to +600℃), excellent self-lubrication, and superior thermal stability, making it ideal for preventing high-temperature valve leakage. Optimized Packing Structure: A combination of layered flexible graphite rings and intermediate reinforcing rings was used. This structure ensures reliable sealing performance while enhancing the overall strength of the packing set to combat valve leakage. Standardized Installation Procedure: The packing was installed layer by layer according to standard procedures, ensuring all ring cuts were staggered. A torque wrench was used to tighten the gland bolts evenly to the recommended torque. After replacing the packing and optimizing the installation process, the control valve resumed stable operation. Following 72 hours of continuous monitoring using a portable volatile organic compound detector at multiple points around the gland, the valve stem seal showed zero leakage.

In a burner system, the control valve acts as a precise “conductor,” managing fuel supply and directly impacting combustion efficiency and safety. How does one scientifically select the correct valve for different fuels like natural gas or fuel oil? Senior Engineer Mr. Mo, with over 30 years of hands-on experience, shares his core insights. This article systematically organizes his expertise to help you master burner valve selection. Universal Burner Valve Selection Guide: Master These Six Points for Success Whether the medium is natural gas or fuel oil, a successful burner valve selection process must comprehensively consider the following six core elements, which form the foundation for stable system operation: Valve Body Material & Corrosion Resistance: Select appropriate corrosion-resistant materials such as stainless steel or special alloys based on the operating environment and the corrosiveness of the medium itself, ensuring long-term valve durability. Electrical Protection & Explosion-Proof Rating: In flammable or explosive atmospheres, it is essential to choose valves with electrical components and overall design that comply with onsite explosion-proof standards, minimizing safety risks. Control Accuracy & Flow Characteristics: Choose valves with the appropriate control precision and flow characteristics to achieve accurate and stable air-fuel ratio control. Flow Capacity (Cv Value): The valve’s flow capacity under a specific pressure drop should be slightly greater than the burner’s actual maximum flow requirement, providing a safety margin and avoiding system bottlenecks. Actuation Type & Power Source: Select electric or pneumatic actuation based on site conditions. Electric valves offer precise control and easy wiring; pneumatic valves provide fast action and excellent explosion-proof performance. The required voltage or air supply pressure must be confirmed. Media Pressure & Temperature: The valve’s pressure rating and temperature tolerance must exceed the media’s actual working pressure and temperature, ensuring seal integrity and structural safety. Core Comparison: Natural Gas vs. Fuel Oil Burner Valve Selection While following universal principles, the specific burner valve selection focus must be adjusted for different fuel properties: Selection Factor Natural Gas Control Valve Fuel Oil Control Valve Media Properties Clean, dry, but leakage must be prevented May contain impurities, be viscous, or corrosive Primary Concern Sealing Performance and Response Speed Clog Resistance and Corrosion/Temperature Resistance Material & Sealing Emphasizes high sealing classes to prevent gas leakage Materials must be oil-resistant and corrosion-resistant; some tolerance for impurities is needed Pressure & Temperature Focus on inlet pressure stability Often faces higher operating temperatures and pressures Recommended Product High-sealing Electric Ball Valves, Control Butterfly Valves Electric V-Port Ball Valves (The V-notch shears media, reducing jamming risk) Focus Analysis: Why Electric Actuation is Preferred for Quick Opening Valves For fast shut-off functions at the burner front end, electric valves demonstrate significant advantages over traditional solenoid valves: Higher Reliability: Electric actuators provide high torque, ensuring stable opening and closing cycles that are less susceptible to misoperation from media pressure fluctuations or impurities. Superior Impurity Resistance: Particularly with electric ball valves, the rotational movement of the ball can effectively cut through or displace small particles, offering a degree of “self-cleaning” and avoiding the jamming issues common in direct-acting solenoid valve designs. More Flexible Control: They can receive standard signals from PLC or DCS systems, enabling more complex interlock control strategies. Therefore, for applications demanding high reliability and media adaptability, an electric quick opening valve is the ideal burner valve selection for rapid switching duties. Conclusion Correct burner valve selection is the first step towards efficient and safe burner operation. Our quick opening electric valves are designed for this purpose, featuring 3-second operation, a lifespan exceeding 100,000 cycles, and revolutionary one-step debugging technology. They are key to enhancing your system’s response and safety. To learn how this product can protect your project, please contact us. We specialize in industrial valves, offering a comprehensive product line covering all control and quick opening valve needs for burner systems. If you have specific burner valve selection challenges or project requirements, just contact us for a customized solution from our expert engineers!

With 18 years of deep expertise in industrial chiller units, GRAT guide vane motors have consistently partnered with leading manufacturers in the industry. Renowned for exceptional reliability, our products have earned global customer trust and become the core power component ensuring stable cooling performance. Having undergone over a decade of rigorous market validation, more than 200,000 GRAT guide vane motors have been deployed worldwide. Our motors offer broad compatibility, supporting all types of centrifugal chillers—including single-stage compression, double-stage compression, variable frequency, and magnetic levitation models. They continuously protect the unit’s “heart” (compressor), ensuring trouble-free operation and establishing a stable temperature safety line for industrial processes. Core Patent Technology DDS Switching Debugging: Based on independent patented technology, this feature allows non-specialists to perform rapid calibration, significantly shortening installation and maintenance cycles. PPD Positioning: Precisely compensates for errors and maintains millimeter-level positioning accuracy. Combined with high-quality imported potentiometers, it guarantees long-term operational stability. Protection in Complex Environments Robust Housing: Constructed from aluminum alloy die-casting with an IP68 protection rating. High-Quality Components: Utilizes imported servo units and resin-encapsulated circuit boards. Anti-Interference: Excellent resistance to electromagnetic interference, making it suitable for challenging industrial environments such as those with high humidity and strong radiation. 18 Years of Reputation: The Choice of Global Customers The GRAT guide vane motor is the preferred choice for many world-renowned manufacturers, including: Dunham-Bush (Central Air Conditioning) Johnson Controls Hitachi Ebara Hisense Hitachi Grundfos Pumps CNOOC, Sinopec, CNPC China Shipbuilding Industry Corporation With over 200,000 units deployed, our motors serve critical cooling applications across the electronics, chemical, and pharmaceutical industries worldwide. GRAT remains committed to continuous product optimization through technological innovation. We aim to provide even more stable and efficient guide vane drive solutions for industrial chiller units, partnering with customers to create a new future in refrigeration.

Application Background As an important inorganic chemical pigment, titanium dioxide is widely used in many industrial fields such as coatings, plastics, and papermaking. Its product performance imposes high requirements on the stability and control precision of the production process. In the sulfuric acid method for titanium dioxide production, key processes like acid digestion and hydrolysis place stringent demands on the corrosion resistance, sealing performance, and control accuracy of valves. The GRAT electric hard seal ball valve, with its excellent corrosion resistance and precise regulation capability, provides a reliable fluid control solution for titanium dioxide production. Operating Conditions Model: GRAT Hard Seal Ball Valve Application: Controlling the flow rate and temperature of sulfuric acid during the acid digestion reaction. Medium: Sulfuric Acid Size: DN50 Material: SUS304 Connection Type: Flanged Control Signal: 4-20mA Power Supply: AC220V Design Life: 6 Years Commissioning Date: March 2014 Location: Hubei, China Product Advantages & Features Precise Control, Enhanced EfficiencyOur hard seal ball valve integrates an electric actuation system, enabling remote control and seamless automation compatibility. Utilizing proprietary PPD positioning technology, it achieves ±0.1% positioning accuracy with an adjustable dead zone of 0.3%–3.0%, ensuring high-precision regulation of media flow in diverse industrial applications. Robust Construction, Long-Lasting PerformanceKey components, including the ball and valve seats, are manufactured from specially formulated hard alloys. These materials offer superior hardness and outstanding wear resistance, effectively withstanding erosion from solid particles and fibrous media. As a result, the hard seal ball valve guarantees over 100,000 cycles of trouble-free operation. High-Temperature and High-Pressure ReliabilityEngineered with specially selected materials and reinforced construction, the hard seal ball valve excels in demanding high-temperature and high-pressure environments. Its durable design ensures long-term stability and safe performance, making it a reliable choice for critical pipeline systems. Compact and Cost-Effective DesignThe hard seal ball valve features a space-saving, compact design that simplifies installation and reduces operational footprint. Suitable for a wide range of media—including water, steam, petroleum, and corrosive substances—this valve minimizes maintenance needs and significantly lowers total lifecycle costs. Performance Results Achieved zero failures and zero leakage after continuous operation for 6 years in sulfuric acid, accumulating over 100,000 cycles. Maintained control accuracy within ±0.5%, precisely regulating sulfuric acid flow and temperature in the acid digestion process, ensuring reaction efficiency exceeded 90%. Internal component wear was less than 0.1mm, withstanding erosion and scouring from solid particles (0.5-2mm diameter) in the sedimentation process. Provided stable gas flow control in the calcination process at 800°C high-temperature conditions, ensuring calcined product whiteness remained above 98%. Achieved precise control speed in the hydrolysis process, reducing maintenance costs by 80% and significantly improving production efficiency. The electric hard seal ball valve holds significant application value in the titanium dioxide industry, where its advantages meet the demands of complex working conditions. The special structural design for high-temperature conditions ensures reliable operation, while its anti-clogging and high-temperature protection features enhance service life and production efficiency. The stringent requirements for performance and selection within the titanium dioxide industry also drive continuous optimization of the hard seal ball valve.

.gtr-container-pqr789 { font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif; color: #333; line-height: 1.6; padding: 16px; box-sizing: border-box; overflow-x: hidden; } @media (min-width: 768px) { .gtr-container-pqr789 { max-width: 960px; margin: 0 auto; padding: 24px; } } .gtr-container-pqr789 h2 { font-size: 18px; font-weight: bold; margin-top: 24px; margin-bottom: 16px; color: #0056b3; } .gtr-container-pqr789 p { font-size: 14px; margin-bottom: 16px; text-align: left !important; word-break: normal; overflow-wrap: normal; } .gtr-container-pqr789 img { height: auto; } .gtr-container-pqr789 blockquote { margin: 20px 0; padding: 10px 20px; border-left: 4px solid #007bff; color: #555; font-style: italic; background-color: transparent; } .gtr-container-pqr789 ul { margin: 16px 0; padding-left: 20px; } .gtr-container-pqr789 ul li { list-style: none !important; position: relative; margin-bottom: 8px; padding-left: 15px; } .gtr-container-pqr789 ul li::before { content: "•" !important; position: absolute !important; left: 0 !important; color: #007bff; font-weight: bold; font-size: 1.2em; line-height: 1; } .gtr-container-pqr789 ol { margin: 16px 0; padding-left: 25px; counter-reset: list-item; } .gtr-container-pqr789 ol li { list-style: none !important; position: relative; margin-bottom: 8px; padding-left: 20px; } .gtr-container-pqr789 ol li::before { content: counter(list-item) "." !important; position: absolute !important; left: 0 !important; color: #007bff; font-weight: bold; font-size: 1em; text-align: right; width: 18px; } .gtr-container-pqr789 strong { font-weight: bold; } In industriellen Automatisierungssteuerungssystemen ist der zuverlässige Betrieb von elektrischen Kugelhähnen entscheidend für die Prozesssicherheit und -effizienz. Die folgende Fallstudie skizziert ein aktuelles Beispiel für die Fehlersuche, bei dem ein elektrischer Kugelhahn, der in einer Gaspipeline eines Industrieparks installiert war, nach Abschluss der Verkabelung nicht öffnete oder schloss. Durch systematische Inspektion und professionelle Analyse identifizierte unser Team schnell die Ursache und implementierte eine effektive Lösung. Wir teilen den Prozess unten zur Branchenreferenz mit. Technische Spezifikationen Anwendungsszenario: Gaspipeline eines Industrieparks Zweck: Hauptabsperrung der Gaspipeline Medium: Erdgas Ventilgröße: DN300 Körpermaterial: WCB Anschlussart: Flansch Steuersignal: Schaltsignal Betriebsspannungsversorgung: AC220V Konstruktionslebensdauer: 6 Jahre Inbetriebnahme: Dezember 2024 Installationsort: Shanghai Nachdem die Kabelverbindung zwischen dem elektrischen Kugelhahn und dem Schaltschrank hergestellt war, stellten die Bediener fest, dass das Ventil sich nicht öffnen oder schließen ließ auf Befehl. Dieser Fehler deaktivierte die Regulierungsfunktion der Gaspipeline und beeinträchtigte direkt die normale Gasversorgung für die Unternehmen des Parks. Fehlersuche & Analyse Das technische Support-Team von GRAT griff umgehend ein. Eine erste Inspektion bestätigte die korrekte Verkabelung, gefolgt von einer systematischen Messung der elektrischen Parameter: Die am elektrischen Stellantrieb gemessene Ist-Spannung betrug nur AC80V, was deutlich unter der Nennspannung von AC220V. Gemäß der Leistungsformel P = UI (die Leistung des Stellantriebs beträgt 1,2 kW) führt bei konstanter Leistung eine Abnahme der Spannung zu einer Erhöhung des Stroms. Der gemessene Betriebsstrom erreichte 18A. Dieser übermäßige Strom löste den eingebauten Überstromschutz des Schaltschranks aus und verhinderte so den Betrieb des elektrischen Kugelhahns. Analyse der Ursache:Der starke Spannungsabfall war in erster Linie auf die lange Kabellänge von 600–700 Metern zwischen dem elektrischen Kugelhahn und dem Schaltschrank zurückzuführen. Über eine so lange Strecke für die Stromübertragung machte der erhebliche Spannungsabfall es unmöglich, die für den normalen Start des Stellantriebs erforderliche Spannung zu erreichen. Wichtige Faktoren, die den Leitungsspannungsabfall beeinflussen, sind: Leitermaterial (z. B. Kupferaderkabel hat einen geringeren Widerstand und einen geringeren Spannungsabfall) Leitungslänge (längere Länge erhöht den Spannungsabfall) Leiterquerschnitt (größerer Querschnitt verringert den Widerstand und den Spannungsabfall) Umgebungstemperatur (höhere Temperatur erhöht den Leiterwiderstand) Diese Situation verdeutlicht eine wichtige Konstruktionsüberlegung: die Verhinderung eines übermäßigen Spannungsabfalls bei der Installation von elektrischen Kugelhähnen, insbesondere über lange Strecken. Lösung & Implementierung Um die Fehlerursache zu beheben, bewerteten wir zwei praktikable Lösungen: Änderung der Nennspannung: Ändern Sie die Betriebsspannung des Stellantriebs von AC220V auf AC380V. Obwohl AC380V eine stabile Spannung und einen geringeren Strom bietet, wurde diese Option aufgrund des Fehlens einer AC380V-Stromquelle vor Ort, hoher Kosten für den Austausch des Stellantriebs und potenzieller Kompatibilitätsprobleme ausgeschlossen. Verlegung des Schaltschranks: Nach Rücksprache mit dem Personal vor Ort wurde der Schaltschrank näher an den Kugelhahn verlegt und die Verkabelung neu installiert. Tests nach der Verlegung bestätigten dass der Kugelhahn den Normalbetrieb wieder aufnahm und den Fehler behob. Implementierungsergebnisse:Nachdem wir uns für Lösung 2 entschieden hatten, führte unser Bauteam den Plan umgehend aus. Der Schaltschrank wurde etwa 50 Meter vom elektrischen Kugelhahn entfernt neu positioniert. Neue Strom- und Steuerkabel wurden gemäß den Spezifikationen installiert. Die Nachrüstungs-Fehlerbehebung und -Tests umfassten: Messen der Spannung am Eingang des Stellantriebs mit einem Präzisionsvoltmeter, Bestätigung einer stabilen AC215V, die die Nennanforderung vollständig erfüllt. Überprüfung des Anlaufstroms mit einem Zangenamperemeter, das einen stabilen Wert von 8,2A anzeigt, innerhalb des normalen Betriebsbereichs. Durchführung mehrerer Öffnungs-/Schließbetriebstests, wobei der elektrische Kugelhahn genau und zuverlässig auf Steuersignale reagierte. Nach 72 Stunden Dauerüberwachung blieben alle Systemparameter stabil, was bestätigte, dass der Fehler vollständig behoben war. Diese erfolgreiche Lösung behebt nicht nur das unmittelbare Problem, sondern liefert auch wertvolle Erkenntnisse für die Planung des Layouts von elektrischen Stellantrieben unter ähnlichen Bedingungen und dient als wichtiger Anhaltspunkt für die zukünftige Projektplanung. Zusammenfassung der Erfahrungen Dieser Fall bestätigt erneut, dass während der Planungs- und Installationsphasen von industriellen Automatisierungssystemen eine umfassende Bewertung der elektrischen Systemparameter und des Geräte-Layouts unerlässlich ist. Besonderes Augenmerk sollte auf Folgendes gelegt werden: Genaue Bewertung der Stromversorgungsentfernungen zur Vermeidung von Gerätefehlfunktionen aufgrund von Leitungsspannungsabfall. Wissenschaftliche Auswahl der Kabelspezifikationen, unter Berücksichtigung größerer Querschnitte für Stromübertragungsszenarien über große Entfernungen. Gewährleistung einer integrierten Planung unter Berücksichtigung von Leistungsanpassung, Geräteplatzierung und Steuerlogik. Die effektive Verwaltung des Spannungsabfalls in elektrischen Kugelhahn-Systemen ist entscheidend für die Zuverlässigkeit. GRAT engagiert sich weiterhin für die Bereitstellung professioneller technischer Dienstleistungen und rigoroser Fehleranalysen und liefert zuverlässige Steuerventillösungen, um die Sicherheit, Stabilität und Effizienz industrieller Systeme zu gewährleisten. Wir freuen uns über Anfragen und die Zusammenarbeit mit Kunden aus verschiedenen Branchen.